In response to a request from Artistic Awards Co. (SIC-3499), Colorado Springs, Colorado, a study was made of possible exposure to lead (7439921) during lead medallion production. An elevated blood lead level had been found in one worker with symptoms of weakness and fatigue. Personal breathing zone air samples obtained from the areas of casting and engraving showed levels of 7.3 to 8.0 micrograms/cubic meter (microg/m3). Samples collected during grinding and buffing of lead medallions indicated lead concentration in the breathing zone of 1300 to 1900microg/m3. Each of four grinding and buffing stations was fitted with a well enclosed ventilation hood. At one station, the ductwork was clogged with buffing wheel material and ducts at the other three stations were disconnected inside the cabinets. Excessive levels of lead in the air resulted from a lack of local exhaust ventilation in this area. Workers in this room wore half face respirators; however, the respirator which was worn by the worker who had the elevated blood lead level failed to pass a fit test. After improvements had been made, the ventilation system was observed to be very effective. Lead exposures during buffing and grinding operations had been reduced to below the limit of detection, 6microg/m3. The author concludes that one worker has been overexposed to lead due to a poorly fitted respirator, and possibly to ingestion of lead deposited on food or drinks.